Blend of chlorotrifluoroethylene homopolymer and chlorotrifluoroethylene vinylidene fluoride copolymer



July l2, 1960 s. GATES ETAL 2,944,997

BLEND oF cHLoRoTRIFLUoRoETHYLENE HoMoPoLYMER AND CHLOROTRIFLUOROETHYLENE VINYLIDENE FLUORIDE COPOLYMER 4 Sheets-Sheet 1 Filed Oct. 3. 1956 ATTORNEY July 12, 1960 s. GATES ETAT. 2,944,997

BLEND OF CHLOROTRIFLUOROETHYLENE HOMOPOLYMER AND CHLOROTRIFLUOROETHYLENE VINYLIDENE FLUORIDE COPOLYMER Filed Oct. 5, 1956 4 Sheets-Sheet 2 STlFFNESS-TEMPERATURE CHARACTERISTICS 0F HOMOPOLYMER, BLEND & COPOLYMER |0o.000 70,000 50,000 HoMoPoLYMER 20,000

5000 o z u BLEND,0.59 VINYLIDENE FLuoRloE 2,000 U r- "z' 5 |,000 u.: 700 (f) vCOPOLYMER,0.522 vTNYEToENE FEuoRT E TEMPERATURE, 0.

gt Z INVENToRs 1.95 STEPHEN GATES DENNIS TTMULLINS A T TORNEV HIGH TEMPERATURE STRENGTH OF BLENDS BASED ON HOMOPOLYMER & DIFFERENT COPOLYMERS July 12, 1960 BLEND oF CHLOROTRIFLUOROETHYLENE HOMOPOLYMER AND CHLOROTRIFLUOROETHYLENE VINYLIDENE FLUORIDE coPoLYMER Filed Oct. 3, 1956 S. GATES El AL 4 Sheets-Sheet 3 STEPHEN GATES DENNIS H. MULLINS A TTORNEY July l2, 1960 s. GATES ETAL 2,944,997 MER AND BLEND OF CHLOROTRIFLUOROETHYLENE HOMOPOLY CHLOROTRIFLUOROETHYLENE VINYLIDENE FLUORIDE COPOLYMER 4 Sheets-Sheet 4 Filed Oct. 3, 1956 INVENToRs STEPHEN GATES DENNIS H. MuLLlNs @Vd/XM ATTORNEY 'weight polymers. 'radation on molding prior practice has been to start with -a resin of very high molecularweight, i.e., melt viscosity l80er above, in the hope of obtaining a resin of the desired. molecular weight after degradation has occurred 'Kduring molding o-r extrusion. This expedient is not I BLEND F CHLOROTRIFLUORETHYLENE HOMOPOLYMER AND CHLORDTRIFLUO- ROETHYLENE VINYLIDENE FLUORIDE C0- PQLYMlER l St. Albans, W. Va., assignors to Union Carbide Corpor ration, a corporation of Delaware v Filed Oct. 3, 1956, Ser. No. 613,702 l 2 Claims. (Cl. 260-45.5)

Fluororesins, of the type represented by chlorotri- 'uoroethylene polymers, have come into increasing prominence in applications where resistance to high temperatures'is required.

ts kateniO Stephen Gates, `South Charleston, and Dennis H. Mullins,

However, the v ery high softeningpoint of these polyv i Vmers, which is so desirable in service, hasposed a, thorny problem to plastic technicians, when confronted with .the problem of molding or extruding theserpolymers. In the rst place, the softening point or plastictemperature of the polymer is beyond the operating tern- 'p'erature' range of Athe usual fabricating machines. While this difficulty canV -be overcome by the design `of yspecial'equipment, the high molding temperatures required pose a specialA difficulty. This is because at moldf ing temperatures of about 250 C. to 300 C., the chlorotriuoroethylene polymers of melt viscosity of 50 degrade to polymers of lower molecular weight of melt viscosity 5 to 10. Such lower polymers do not provide 'the strength, toughness, and freedom from heat embrit-l tlement which are obtained With the higher molecular Inorder to compensate for this ldegwholly lsuccessful as the very high molecular Weight polymers require even higher processing temperatures, i.e., above 300 C., which in turn increases the molecular degradation.A Thus, vin practice, acompromise must -be drawn by selecting lthe highest molecular weight of l*the -nal degraded polymers which is consistent .with a practical processing temperature for the initial polymer Even so, such processing w of higher molecular weight. temperatures are beyond the range ofthe equipment commonly used.

A wayhas now been found to mold, mill or extrude This is accomplished by blending Such a blend required, the degradation problem is minimized.

; demonstrated that the blends will flux at lower tem- "iluoroethylene polymers in all proportions.

fby weight; -truded at lower temperatures than are required for the Patented July l2, 1960 ice I The copolymers of chlorotrifluoroethylene and vinylidene fluoride 'which are of value as uxing `or blending agents for chlorotriuoroethylene polymers may be divided into two classes. The rst, and preferred class, are those copolymers containing from 1 to 8 percent by weight combined of vinylidene uoride in the copolymer. These copolymers are compatible with chlorotri- Also, they are leasily prepared as free-owing granular polymers which facilitates mechanical mixing with the chlorotriviluoroethylene polymers.

The second class are those copolymers containing from 8 to 20 percent by weight of combined vinylidene iluoride.4 These copolymers are not.comp'atible in all "proportions-with the chlorothriiluoroethylene resins, but 'infthe rangewhere the two resins are miscible, these copolymers containing a higher amount of vinylidene fluoride also serve as processing or uxing agents for lthe base polymer.

While the fuly compatible copolymers containing from y1% to 8% by weight of vinylidene fluoride are miscible in all proportions with chlorotriuoroethylene polymers,

Athe more usefulblends will contain at least 0.2% by weight of Vcontained vinylidene fluoride, such as may be (obtained by blending one part by weight of a copolyfmer containing 11% vinylidene fluoride with four parts byweight vof the chlorotriuoroethylene polymer. The

vpreferred blends will contain at least 0.5 by weight of contained vinylidene uoride, such as may be obtained ,by blending 10 parts by weight of a 5% copolymer with 90 parts'by weight of the chlorotriuoroethylene polymer. The advantages gained in processability by blending tend to be oli-set by undue loss of strength at high .temperatures when the blend contains more than 3% to 5% by weight of contained vinylidene fluoride.

'Ihe partially compatible copolymers containing from :8% to 20% vinylidnee uoride will form useful blends when the homopolymer constitutes at least 50% by Weight of the blend, and the proportion of the copolymer in the blend is 'such that the vinylidene uoride content of the'blend is from 0.5% to 10% by weight of the blend. Preferably, such blends will contain at least by weight of the homopolymer, and the vinylidene uoride content of the blend is from 0.5% to 5% All of such blends may bemilled or exhomopolymer;

The distinguishing characteristics of the blends as op- .posed` to the properties of theV chlorotriuoroethylene homopolymers or its copolymer with vinylidene fluoride will Vbe presented from several aspects:

` -M'llng and molding characteristics Milling tests o n a steam-heated, two-roll mill have peratures than the homopolymer, and when the copolymer blended is of optimum vinylidene uoride content, at lower temperatures than copolymers of the sar'ne vinylidene uoride content asf the blend.4

The results of the tests are given below, the homopolymers used for milling and-blendinghaving a melt l,viscosivty of 55, the termfViFg appearing in the table and others "to follow standing for vinylidene iiuoride.Y

.. 1 Lowest milling temperature at which a continuous well-fluxed sheet which adheres to the rolls, can be formed on the mill.

On the basis of these tests, and as conlirmed by other `tests to be discussed later, a copolymerv containing 4% to 7% of vinylidene iluoride is preferred for blending. In wire-coating studies, it was found that the blends vextruded faster, and at lower temperatures, thanthe homopolymer. Also, because the blends llowmore readily in molding, pieces having thin sections can be injection- ,molded, whereas the homopolymers can be injectionmolded in thin sections only with difculty and With many rejects.

Reduced molecular weight degradation As previously mentioned, the high temperatures required to process the homopolymer cause the resin to degrade in molecular weight during milling, molding and extrusion operations. Thus a commercial grade of homopolymer with a iiow index of 7.5 mg./min. at 265 C.

(melt viscosity of 55 at 230i C.) will degrade to a flow` index of 21.6 (melt viscosity 21) after 30 minutes of milling (loose banding) at 195 C.

On the other hand, blends of the homopolymer and copolymer show much less degradation on processing weight of the above homopolymer with one part of a copolymer containing 2.6% vinylidene fluoride had a flow index of 13.2 after 5 minutes milling at 195 C., and the iiow indexincreased to only 17 after an additional milling period of 25 minutes.

AFlow index is the rate at which resin at 265 'C. is forcedk through a die having a diameter of 0.0825 inch under an applied pressure of 250 p.s.i.

Melt viscosity is defined as the viscosity in megapoises of the resin at 230 C. as measured on a parallel plate `plasto'meter by the process described by G. J. Dienes and H. F. Klemm in the Journal of Applied Physics, vol. 17, pages 458-471 (1946). The melt viscosity is employed herein as a measure of molecular weight of the resin.

The molecular weight degradation of the above homovpolymers and the relative stability of the above blend on milling is shown in Figure 1.

Properties at high temperature An outstanding and surprising characteristic of the blends of this invention is that, although the blends may be milled, extruded or molded at lower fabricating temperatures than the homopolymers and even the copolymers of comparable vinylidene fluoride content, the ultimate strength of the blends at high temperatures is not significantly different from that of the homopolymer. Thus, ease of working is obtained without sacrice of the service properties at high temperatures of the chloro- -triuoroethylene homopolymers.

The temperature-stiffness relationship of homopolymers, copolymers and blends were studied by means of secant tensile modulus measurements over a wide temperature range in an Instron tensile tester. The secant tensile modulus is dened as 100 times the force in pounds per square inch required to extend the specimen one percent. This modulus varies inversely with the temperature'of the specimen.

Data in Figure 2 show that a blend containing 0.59%

Vthan the homopolymer. Thus, a blend of` three partsby of vinylidene fluoride, which is based on a homopolymer (melt viscosity 55) and a copolymer containing 5.53 percent of vinylidene iluoride, has a stillness-temperature curve which closely resembles that of the homopolymer. On the other hand, a copolymer of comparable vinylidene lluoride content, 0.5% is significantly softer than either over the whole temperature range.

The temperature (T3) at which a stiiness modulus of 1000 p.s.i. is reached has been selected as a basis for comparison of diierent iiuororesins as it represents a potential maximum use-temperature above which the crystals begin to melt and the plastics become sosoft that they will flow under very light loads. With reference to Figure 2, this temperature (T3) is 221 C. for the homopolymer, 220 C. for the blend, and only 207 C. for the copolymer containing 0.5% vinylidene fluoride.

Moreover, this outstanding resistance to softening at high temperatures is obtained only by blending homopolymcrs and copolymers; it cannot be obtained by blending copolymers of different vinylidene iuoride content to obtain a blend of Vequivalent vinylidene lluoride content. This is shown by the data in the table to follow:

As previously mentioned, thevinylidene fluoride content of the copolymer has an important eiect on its blending. properties. To demonstrate this, a series of copolymers of different vinylidene uoride contents were blended with a homopolymer of melt viscosity 55, to form two series of blends, one series -having a vinylidene fluoride content of 0.5% to 0.7%, and the other series having a vinylidene fluoride content of 1.6% to 1.8%. The T3 temperature of these blends was then plotted against the vinylidene fluoride content of the copolymer blended with the results shown in Figure 3. Also shown for comparison is the T3 temperature of the copolymers themselves, plotted against their vinylidene iluoride content. As shown, the copolymers alone becomerincreasingly softer as the vinylidene fluoride content increases. On the other hand, for a constant level of vinylidene uoride content in .the blend, the T3 temperature in the blend increases with increasing vinylidene fluoride content of the copolymer blended, until when the copolymer blended contains from 4% to 7% of. vinylidene fluoride, the T3 temperature approaches that of the homopolymer itself. When the copolymer blended contains from 5% to 6% vinylidene uoride, the T3 temperatures for the homopolymer and the blends are practically identical.

Properties at low temperatures While the blends resemble the chlorotrifluoroethylene homopolymer in their retention of strength at elevated temperatures, they retain the freedom from brittleness at low temperatures which is characteristic of the chlorotriiluoroethylene-vinylidene fluoride copolymers. Thus, brittle temperatures range from 16 C. for the homopolymer of melt viscosity 55 down to -18 C. for a copolymer containing 6.53% vinylidene iiuoride. Copolymers containing 0.5% to 1.8% vinylidene fluoride have brittle temperatures from 10 C. to -4 C. Blends of copolymers and homopolymers also containing from 0.5% to 1.8% vinylidene .iiuoride also have approximately the same range of brittle temperatures.

acrilico? Molecular weight, composition and structure of copolymers The molecular weight of the copolymer l'blended has fsome effectl on 4the properties of the blend, but is fmuoh less pronounced than the e'ifect of `the vinylidene uoride content of the copolymer on the blend properties. To demonstrate this, copolymers of approximately the `same molecular weight but differing in composition, fas

well as copolymers of the same composition, 'but dileiring in molecular weight, were blended with :a .homopolymer of melt viscosity 55 to form a series -of blends. The properties of these blends were as follows:

1 I0=Intriusic viscosity, a measure of molecular weight. This is determined as follows:

One hundred milligrams of resin are dissolved in 50 nil. 1,1,3-triuoropentachloropropane under reflux. A portion of the solution is filtered into a hot (9S-99 C.) modied-Ubblehode viscometer through a sintered glass funnel which is maintained at 100 C. or more by means of a steam jacket. The viscometer is completely immersed in the vapors of retluxf lng 2-butanol (99 0.), and the reflux time of the resin solution is determine?. The intrinsic viscosity is calculated according to the following equa ion:

where t=tirue of elux of the resin solution t=time of eux of the pure solvent c=concentration of resin in g./100 ce.

The eiect of extrapolating to zero concentration has been found to produce only a negligible correction, and is omitted in the present calculation.

It will be seen from the above table that the composition of the copolymer has more effect on its high temperature properties as measured by the T3 temperature, than does the molecular weight of the copolymers. However, blends made from the copolymers of higher molecular weight have lower brittle temperatures.

Thus, the copolymers useful in this invention may have intrinsic viscosities varying from 0.5 to 5.0, with the preferred range being 0.75 to 3.0.

As previously stated, the copolymers containing from 1% to 8% vinylidene fluoride are preferred because blends containing such copolymers retain the high temperature properties of the base polymer. However, copolymers containing from 8% to 20% vinylidene uoride are useful fluxing agents for the homopolymer and the T3 temperatures of such blends are in the useful range. Temperature-stiffness data on such blends with a homopolymer of melt viscosity 55 are given in the table to follow:

Copolymer ViFz Milling Temperature-Stiness Data Blended, Content Temp., Percent of Blend, C.

ViFz Percent T3, C. T4, CJ T5, C!l

8. 1 0. 6 190 192 129 48 8. 1 1. 6 190 192 126 43 9. 6 0. 6 190 195 142 51 9. 6 1. 6 190 185 122 12. 7 0. 6 190 188 144 5l 12. 7 1. 6 190 187 126 42 16. 4 0. 6 190 190 184 51 16. 4 l. 6 190 195 136 46 19. 0.6 190 202 149 55 19. 5 1. 6 190 201 144 o4 i Tl-Temperature at which modulus is 10,000 p.s.i. 2 'P5-Temperature at which modulus is 100,000 psi.

v 'Ihe copolymers of chlorotritluoroethylene and vinylidene fluoride may be either uniform or non-uniform in polymer distribution. As vinylidene fluoride is the faster component in the copolymerzation to :form the copolymers useful in this invention, a non-uniform polymer results when the monomers are charged in a given ratio, and polymerization 'conducted without additions or withdrawals `of monomers. A uniform copolymer vresults when the ratio of monomers is maintained approximately constant throughout the polymerizatim'l.Y This'is usually done by additions of vinylidene vuoi'ide lto "the charge throughout the polymerization. The following table shows the approximate percentage of vinylidene uorid'e to be maintained 'in the monomer mixture in order 'to obtain a copolymer of the stated composition:

Vlnylldene Vlnylldene Fluoride, Fluoride, percent by percent by lvif/[eight ln veiglt ln onomer opo ymer Mixture i Both the copolymers and the homopolymers may be made using as catalysts the bis(perlluoroacy1) peroxides disclosed in U.S. Patent No. 2,700,662 to D. M. Young and B. Thompson.

The vinylidene fluoride content of the copolymer has an important effect on the high temperature properties of the blend, regardless of whether the copolymer is Molecular weight of homopolymer The molecular weight of the homopolymer blended may be varied over a wide range, and it is necessary only that the homopolymer be a solid of adequate strength and toughness, as shown by a minimum melt viscosity of 2. This corresponds to an `intrinsic viscosity of about 0.5, as heretofore dened.

Tests have shown that the processing temperatures of homopolymers having such diverse melt viscosities as 5, 50 and 80 can be reduced by blending with copolymers. Preferably, therefore, the homopolymer should have an intrinsic viscosity of at least 0.75. All of such homopolymers having intrinsic viscosities above 0.5 are highmelting resins, as distinguished from oily, greasy or waxy, low-molecular weight polychlorotriuoroethylenes commonly used as plasticizers.

The following example will show one method of mixing the homopolymer and copolymer. Other methods of mixing involve making dispersions or organosols of the blends by methods known in the art. Suitable dispersants include mixtures of ketones, such as diisobutyl ketone, and aromatic hydrocarbons, such as xylene. In baking such organosols to form coatings, the copolymer greatly improves the flow-out properties of the homopolymer and reduces the fusion temperature.

Example 1.-A mechanical mixture consisting of equal parts of a chlorotriiluoroethylene-vinylidene lluoride copolymer which contained 6.25 percent vinylidene fluoride, by analysis, and a chlorotriiluorethylene homopolymer (melt viscosity 55) uxed readily on a laboratory two-roll mill heated to C.

Inasmuch as the homopolymer could not be iluxed at this temperature, the value of the copolymer as a processing aid is apparent.

The following data demonstrate that the improvements obtained by blending do not impair the physical properities of the base homopolymer. y

` l As determined on a Scott L-6 Tensiley Tester operating at an ambient temperature of 25C. and at a constant rate of elongation of 48 in. per mln.

2 A.S.T.M. Method D747-50. 3 A.S.T.M. Method- D-1043-51. TF ls the point corresponding to 135,000 p.s.l. and T4 to 10,000 p.s.1. on the stinesstemperature curve.

l Tests run of annealed samples. The'other tests are on quenched l samples. v

What is claimed is:

1. A plastic composition having a secant tensile modulus above 1000 lbs. per-sq. in at temperatures below 215 C. comprising -a blend of a solid vresinous homopolymer of chlorotrifluoroethylene intimately admixed with a copolymer of chlorotriuoroethylene and vinylidene fluoride containingvfrom 5% to 6% by weight of viny-lidene'uoride and from"94`% 'to 95% by weight of chlorotrifluoroethyleneV and having an intrinsic viscosity of, 0.75 to3.0, the proportions of the homopolymer and .copolymer in the blend being such that the vinylidene iluoride content of the blend is at least 0.5% by weight and not more-than 1,8% by weight. k v 2;.` A plastic composition Ias claimed in claim 1 in which the copolymer of chlorotriuoroethylene and vinylidene 'uorde is formed by polymerizing a monomer mixture containing from 3.0% to 3.6% by weight of vinylidene `fluoride and in which mixture the ratio of vinylidene uoride monomer to chlorotriuoroethylene monomer is 'maintained approximately constant throughout the polymerization.V

References Cited-in the file of this patent V.UNITED STATES PATENTS Teers ket ai Nov. Y13, v19u56` 2,789,959 Smith Apr. 23, 1957 

1. A PLASTIC COMPOSITION HAVING A SECANT TENSILE MODULUS ABOVE 1000 LBS. PER SQ. IN. AT TEMPERATURES BELOW 215*C. COMPRISING A BLEND OF A SOLID RESINOUS HOMOPOLYMER OF CHLOROTRIFLUOROETHYLENE INTIMATELY ADMIXED WITH A COPOLYMER OF CHLOROTRIFLUOROETHYLENE AND VINYLIDENE FLUORIDE CONTAINING FROM 5% TO 6% BY WEIGHT OF VINYLIDENE FLUORIDE AND FROM 94% TO 95% BY WEIGHT OF CHLOROTRIFLUOROETHYLENE AND HAVING AN INTRINSIC VISCOSITY OF 0.75 TO 3.0, THE PROPORTIONS OF THE HOMOPOLYMER AND COPOLYMER IN THE BLEND BEING SUCH THAT THE VINYLIDENE FLUORIDE CONTENT OF THE BLEND IS AT LEAST 0.5% BY WEIGHT AND NOT MORE THAN 1.8% BY WEIGHT. 